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is that a little chunk of aluminum on the lowest dog clutch?

those dogs are getting the edges whacked big time.

usually the needles are scored or the cage is tweaked, can't tell from the pix.

usually the dog clutches bottom out on the other gear so you deff have it sticking out too far. wrong bearing? some goop keeping it from seating? can you see the prob at the bottom of the bearing where the machined seat is?
 
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